Wheel assemblies

ABSTRACT

A hub assembly includes a retainer housing, a retaining member, a biasing element, and an occlusion. The retainer housing includes a wheel mounting sleeve and a pin sleeve. The wheel mounting sleeve includes an axle bore configured to receive an axle. The pin sleeve has a first end and a second end. The pin sleeve includes a conduit between the first end and the second end. The first end is in fluid communication with the axle bore. The retaining member and the biasing element are in the conduit. The retaining member is configured to engage a groove in an axle. The biasing element is configured to bias the retaining member towards the axle bore. The occlusion is proximate to the second end of the pin sleeve. The occlusion is configured to inhibit the retaining member from exiting the conduit at least prior to coupling the hub assembly to a wheel.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 15/588,057, filed on May 5, 2017 and issued as U.S. Pat. No.10,279,624 on May 7, 2019, which is a continuation U.S. patentapplication Ser. No. 15/003,468, filed on Jan. 21, 2016 and issued asU.S. Pat. No. 10,189,307 on Jan. 29, 2019, which is a continuation ofU.S. patent application Ser. No. 14/678,371, filed on Apr. 3, 2015 andissued as U.S. Pat. No. 9,266,391 on Feb. 23, 2016, which is acontinuation of U.S. patent application Ser. No. 14/085,535, filed onNov. 20, 2013 and issued as U.S. Pat. No. 9,010,877 on Apr. 21, 2015,which is a continuation of U.S. patent application Ser. No. 13/406,211,filed on Feb. 27, 2012 and issued as U.S. Pat. No. 8,616,657 on Dec. 31,2013, which is a continuation of U.S. patent application Ser. No.11/944,322, filed on Nov. 21, 2007 and issued as U.S. Pat. No. 8,147,005on Apr. 3, 2012 and reissued as U.S. Pat. No. RE45,101 on Sep. 2, 2014,and U.S. patent application Ser. No. 14/085,535, filed on Nov. 20, 2013and issued as U.S. Pat. No. 9,010,877 on Apr. 21, 2015, is acontinuation of U.S. patent application Ser. No. 13/673,655, filed onNov. 9, 2012 and issued as U.S. Pat. No. 8,616,658 on Dec. 31, 2013,which is a continuation of U.S. patent application Ser. No. 11/944,322,filed on Nov. 21, 2007 and issued as U.S. Pat. No. 8,147,005 on Apr. 3,2012 and reissued as U.S. Pat. No. RE45,101 on Sep. 2, 2014, each ofwhich is incorporated herein by reference in its entirety.

BACKGROUND Field

The present invention generally relates to wheel assemblies and themanner of their mounting to and removal from an axle, and moreparticularly, to wheel and hub assemblies used on refuse carts and thelike.

Description of the Related Art

The use of plastic wheels on a variety of products has dramaticallyincreased in recent years. One area where such plastic wheels have beenwidely employed is on wheeled refuse or garbage carts or bins of thetype commonly employed by homeowners for their trash. These cartstraditionally have plastic wheels that are mounted on the ends of ametal axle by a hub member or push-on hat fastener (sometimes referredto as “pawl nut”). The wheel hub is hammered onto the end of the axle tohold the wheel in place. Removal of such plastic wheels in order toreplace or repair the wheel or the cart can be difficult because thehammered push-on hat fasteners or hubs require special tools for theirremoval, or essentially must be destroyed to remove them from the axle.Sometimes this process also damages the axles. Wheel-mounting sleeveassemblies have been devised which snap-on to a pre-machined axle tohold the wheel to the axle. However, these snap-on wheel assemblies havebeen unduly complex, visually unappealing, and poorly suited to theshock loading and vibration commonly encountered.

SUMMARY

The design of certain prior wheel and hub assemblies limits the extentof automatic assembly of a wheel and hub assembly because the pin andspring would be expelled from the wheel assembly without a portion ofthe wheel to keep them in place. The hub assembly may be specificallyoriented such that the pin and spring do not fall out until coupling toa wheel. However, manipulation of the hub assembly such as transporting,dropping, turning, and especially vibration caused by automatingequipment can cause the pin and spring to become lost before assembly,increasing costs and slowing assembly due to insertion of replacementparts. Additionally, foreign debris can enter the open end of a pinsleeve all the way until assembly with a wheel. Thus, the pin and springare generally installed during coupling of the wheel and a hub assembly.Upon disengagement of the wheel from such hub assemblies, which mayoccur when a wheel assembly is broken (e.g., due to splitting of thewheel from shock loading), the pin and spring can be expelled from thehub assembly to be lost or damaged.

At least one aspect of the present invention is the realization of theadvantages gained from a restraining element such as a plug thatprevents the pin and spring from being separated from the hub assemblyupon manipulation without being coupled to a wheel. Once the plug iscoupled to the pin sleeve after the pin and spring are inserted therein,the hub assembly can be fully manipulated without causing separation ofthe components because the plug prevents the pin and spring from comingout of the pin sleeve. The hub assembly can thus be formed well beforeit is coupled to the wheel, allowing resources to be allocated withoutregard to the quantity of any component (i.e., more hub assemblies canbe made even if there are no wheels to couple them to because they canbe stored without the fear of losing pieces). The plug also allows fullyautomated assembly because the hub assembly can be oriented in anydirection and can be positioned by a vibratory feeder. Moreover, if awheel is damaged, the hub assembly, which is typically the moreexpensive component, can be coupled to another wheel because all of itspieces are still in tact and accounted for.

In certain embodiments, a wheel assembly comprises a wheel and a hubassembly mounted in the wheel. The wheel includes a sleeve bore. The hubassembly includes a retainer housing, a retaining member, a biasingelement, and a restraining element. The retainer housing includes awheel mounting sleeve and a pin sleeve. The wheel mounting sleeveincludes an axle bore configured to receive an axle and configured to beinserted within the sleeve bore of the wheel. The pin sleeve includes afirst end, a second end, and a conduit between the first end and thesecond end. The first end is in fluid communication with the axle bore.The first end includes a shoulder extending into the conduit. Theretaining member is disposed within the conduit of the pin sleeve. Theretaining member includes a lip wider than the shoulder. The lip and theshoulder interact to prevent the retaining member from exiting the firstend of the pin sleeve. The biasing element is disposed within theconduit of the pin sleeve and is configured to bias the retaining membertowards the axle bore. The retaining member is configured to operativelyengage a groove in an axle. The restraining element is configured toprevent the retaining member from exiting the second end of the pinsleeve.

In certain embodiments, a hub assembly comprises a retainer housing, aretaining member, a biasing element, and a restraining element. Theretainer housing includes a wheel mounting sleeve and a pin sleeve. Thewheel mounting sleeve includes an axle bore configured to receive anaxle and configured to be inserted within a sleeve bore of a wheel. Thepin sleeve includes a first end, a second end, and a conduit between thefirst end and the second end. The first end is in fluid communicationwith the axle bore. The first end includes a shoulder extending into theconduit. The retaining member is disposed within the conduit of the pinsleeve. The retaining member includes a lip wider than the shoulder. Thelip and the shoulder interact to prevent the retaining member fromexiting the first end of the pin sleeve. The biasing element is disposedwithin the conduit of the pin sleeve and is configured to bias theretaining member towards the axle bore. The retaining member isconfigured to operatively engage a groove in an axle. The restrainingelement is configured to prevent the retaining member from exiting thesecond end of the pin sleeve.

In certain embodiments, a method of manufacturing a wheel assemblycomprises forming a wheel and forming a retainer housing. The wheelincludes a sleeve bore. Forming the retainer housing includes forming awheel mounting sleeve and forming a pin sleeve. The wheel mountingsleeve includes an axle bore configured to receive an axle andconfigured to be inserted within the sleeve bore of the wheel. The pinsleeve includes a first end, a second end, and a conduit between thefirst end and the second end. The first end is in fluid communicationwith the axle bore. The first end includes a shoulder extending into theconduit. The method further comprises positioning a retaining memberwithin the pin sleeve. The retaining member includes a lip wider thanthe shoulder. The lip and the shoulder interact to prevent the retainingmember from exiting the first end of the pin sleeve. The method furthercomprises positioning a biasing element in the pin sleeve to bias theretaining member towards the axle bore. The method further comprisesoccluding the second end of the pin sleeve, thereby preventing theretaining member from exiting the second end of the pin sleeve. Themethod further comprises inserting the wheel mounting sleeve of theretainer housing into the sleeve bore of the wheel, thereby coupling theretainer housing to the wheel.

For purposes of summarizing the invention and the advantages achievedover the prior art, certain objects and advantages of the invention havebeen described herein above. Of course, it is to be understood that notnecessarily all such objects or advantages may be achieved in accordancewith any particular embodiment of the invention. Thus, for example,those skilled in the art will recognize that the invention may beembodied or carried out in a manner that achieves or optimizes oneadvantage or group of advantages as taught or suggested herein withoutnecessarily achieving other objects or advantages as may be taught orsuggested herein.

All of these embodiments are intended to be within the scope of theinvention herein disclosed. These and other embodiments will becomereadily apparent to those skilled in the art from the following detaileddescription of the preferred embodiments having reference to theattached figures, the invention not being limited to any particularpreferred embodiment(s) disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the inventiondisclosed herein are described below with reference to the drawings ofpreferred embodiments, which are intended to illustrate and not to limitthe invention.

FIG. 1 is a top perspective view of a refuse cart including a wheelassembly mounted thereto.

FIG. 2A is a top perspective view of a side of an example embodiment ofa wheel assembly.

FIG. 2B is a bottom perspective view of another side of the wheelassembly of FIG. 2A.

FIG. 3A is a top perspective view of a side of another exampleembodiment of a wheel assembly.

FIG. 3B is a bottom perspective view of another side of the wheelassembly of FIG. 3A.

FIG. 3C is a top perspective cross sectional view of the wheel of thewheel assembly of FIG. 3A.

FIG. 4A is a top perspective view of a side of an example embodiment ofa hub assembly.

FIG. 4B is a bottom perspective view of another side of the hub assemblyof FIG. 4A.

FIG. 4C is a cutaway top perspective view of the hub assembly of FIG.4A.

FIG. 4D is a cross-sectional view of the hub assembly of FIGS. 4Aengaged with an axle.

FIG. 5A is a cutaway top perspective view of the wheel assembly of FIG.2A.

FIG. 5B is a cross-sectional view of the wheel assembly of FIG. 2Aengaged with an axle.

FIG. 5C is a cutaway top perspective view of the wheel assembly of FIG.3A.

FIG. 5D is a cross-sectional view of the wheel assembly of FIG. 3Aengaged with an axle.

FIG. 5E is a cross-sectional view of an example embodiment of a wheelassembly engaged with an axle and a cart body.

FIG. 6A is a cutaway top perspective view of a side of an exampleembodiment of a retainer housing.

FIG. 6B is a top perspective view of another side of the retainerhousing of FIG. 6A.

FIG. 7 is a top perspective view of an example embodiment of a retainingmember.

FIG. 7A is a top perspective view of another example embodiment of aretaining member.

FIG. 7B is a top plan view of another example embodiment of a retainingmember.

FIG. 8 is a top perspective view of an example embodiment of a biasingelement.

FIG. 9A is a top perspective view of an example embodiment of arestraining element.

FIG. 9B is a cross-sectional view of the restraining element of FIG. 9A.

FIG. 10A is a top perspective cross-sectional view of another exampleembodiment of a hub assembly.

FIG. 10B is a top perspective cross-sectional view of still anotherexample embodiment of a hub assembly.

FIG. 10C is a top perspective cross-sectional view of yet anotherexample embodiment of a hub assembly.

FIG. 10D is a top perspective cross-sectional view of yet still anotherexample embodiment of a hub assembly.

DETAILED DESCRIPTION

Although certain preferred embodiments and examples are disclosed below,it will be understood by those in the art that the invention extendsbeyond the specifically disclosed embodiments and/or uses of theinvention and obvious modifications and equivalents thereof. Thus, it isintended that the scope of the invention herein disclosed should not belimited by the particular disclosed embodiments described below.

The wheel assemblies described herein can be used in connection withnumerous wheeled devices. FIG. 1 illustrates an example embodiment of arefuse cart comprising plurality of wheel assemblies 110 mounted on anaxle 150 to the lower end of the cart body 102. A hinged lid 104optionally can be provided, and the cart 100 can be tilted or tippedabout the wheel assemblies 200 using handle 106 so as to enable rollingof the cart 100 for the transport of refuse, for example between alocation for filling the cart 100 and a location for pickup by a refusedisposal company. The lower end of the cart body 102 optionally includesa wheel well or recess area 108 configured to receive wheel assemblies110, for example to protect the wheel assemblies 110 and as a cosmeticstructure. As described in detail below, the wheel assemblies 110 aresecured on the axle 150 by a hub assembly 400. The wheel assembliesdescribed herein are also suitable for use with other wheeled productssuch as wagons, wheeled food and beverage coolers, barbecues, wheeledtoys, small refuse containers, and the like.

FIG. 2A is a top perspective view of a side of an example embodiment ofa wheel assembly 200 (e.g., an “outer” side when the wheel assembly ismounted to a cart 100 via an axle 150). FIG. 2B is a bottom perspectiveview of another side of the wheel assembly 200 of FIG. 2A (e.g., an“inner” side when the wheel assembly is mounted to a cart 100 via anaxle 150). When viewing a cart 100 comprising a wheel assembly 200, auser can generally see the entire outer side of the wheel assembly 200,but a portion of the inner side of the wheel assembly 200 can be atleast partially obscured by the lower end of the cart body 102 (e.g., asdepicted in FIG. 1). The wheel assembly 200 comprises a wheel 202 and ahub assembly 400 (described below) coupled to (e.g., mounted on) thewheel 202.

The wheel 202 illustrated in FIGS. 2A and 2B is blow molded. In certainembodiments, blow molding includes coupling two female mold cavities,extruding molten material (called a “parison”), and expanding thematerial by blowing air into the parison. After the material hassufficiently hardened, the wheel 202 is removed from the molds. Incertain embodiments, treads 204 and spokes 206 are integrally formedduring the molding process. The treads 204 can help the wheel 202 tofrictionally engage a surface during rolling movement and can enhancethe appearance of the wheel 202. The spokes 206 can help evenlydistribute forces acting on the wheel 202. Other features of the wheel202 may also be integrally formed by modifying the mold. The blowmolding process forms hollow interior surfaces (see FIG. 5A) that canreduce the amount of material used in creation of the wheel 202, butalso provide strength by creating certain shapes. In some embodiments,forming the wheel 202 includes trimming or “deflashing” the wheel 202.In certain such embodiments, the wheel 202 is deflashed while in a moldcavity. In certain embodiments, the wheel 202 comprises plastic (e.g.,high density polyethylene (HDPE) (e.g., high molecular weight HDPE)).

FIG. 3A is a top perspective view of a side of another exampleembodiment of a wheel assembly 300 (e.g., an “outer” side when the wheelassembly is mounted to a cart 100 via an axle 150). FIG. 3B is a bottomperspective view of another side of the wheel assembly 300 of FIG. 3A(e.g., an “inner” side when the wheel assembly is mounted to a cart 100via an axle 150). When viewing a cart 100 comprising a wheel assembly300, a user can generally see the entire outer side of the wheelassembly 300, but a portion of the inner side of the wheel assembly 300can be at least partially obscured by the lower end of the cart body 102(e.g., as depicted in FIG. 1). The wheel assembly 300 comprises a wheel302 and a hub assembly 400 (described below) coupled to (e.g., mountedon) the wheel 302.

The wheel 302 illustrated in FIGS. 3A and 3B is injection molded. Incertain embodiments, injection molding includes coupling a male mold anda female mold and injecting molten material therebetween. After thematerial has sufficiently hardened, the wheel 302 is removed from themolds. In certain embodiments, treads 304 and spokes 306 are integrallyformed during the molding process. The treads 304 can help the wheel 302to frictionally engage a surface during rolling movement and can enhancethe appearance of the wheel 302. The spokes 306 can help evenlydistribute forces acting on the wheel 302. Other features of the wheel302 may also be integrally formed by modifying the mold. The injectionmolding process can form corrugated and hollow interior surfaces (seeFIG. 3C) that can reduce the amount of material used in creation of thewheel 302, but also provide strength by creating certain shapes. Incertain embodiments, the wheel 302 comprises plastic (e.g., high densitypolyethylene (HDPE) (e.g., high molecular weight HDPE)). FIG. 3B alsoshows that cavities 308 may be formed under the treads 304, and in someembodiments exposed (e.g., on the inner side of the wheel 302).

FIG. 3C illustrates a cross-sectional view of the wheel 302 of the wheelassembly 300. The wheel 302 includes a sleeve bore 310. In someembodiments, the sleeve bore 310 includes a first end, a second end, anda conduit therebetween. In certain embodiments, one of the ends may beclosed. The sleeve bore 310 may be centered within the wheel 302 suchthat an axle 150 inserted into the sleeve bore 310 (e.g., into a hubassembly 400 at least partially disposed within the sleeve bore 310) canuniformly rotate. In certain embodiments, the sleeve bore 310 isconfigured to receive a wheel mounting sleeve of a hub assembly (e.g.,the wheel mounting sleeve 302 of the hub assembly 400). Referring toFIG. 2B, the wheel 202 also includes a sleeve bore 210.

It will be appreciated that wheel assemblies described herein maycomprise wheels manufactured using other processes (e.g., rotational orcompression molding) and/or having other features. For example, thewheel may have a separate tread attached to the outer surface. Foranother example, the wheel may comprise materials such as wood, metal,rubber, combinations thereof, etc.

FIG. 4A is a top perspective view of a side of an example embodiment ofa hub assembly 400 (e.g., an “outer” side when the hub assembly 400 ismounted to a wheel that is mounted to a cart 100 via an axle 150). FIG.4B is a bottom perspective view of another side of the hub assembly 400of FIG. 4A (e.g., an “inner” side when the hub assembly 400 is mountedto a wheel that is mounted to a cart 100 via an axle 150). FIG. 4C is acutaway top perspective view of the hub assembly 400 of FIG. 4A, whichillustrates some of the inner components of the hub assembly 400.

The hub assembly 400 comprises a retainer housing 600, a retainingmember 700, a biasing element 800, and a restraining element 900. Eachof the components of the hub assembly 400 is described in detail below.The retainer housing 600 includes a wheel mounting sleeve 602 includingan axle bore 606 configured to receive an axle 150 and configured to beinserted within the sleeve bore 310 of a wheel 202, 302. The retainerhousing 600 also includes a pin sleeve 604 including a first end 607, asecond end 608, and a conduit 610 between the first end 607 and thesecond end 608 (FIGS. 6A and 6B). The first end 607 includes a shoulder612 extending into the conduit 610. The retaining member 700 is disposedwithin the conduit 610 of the pin sleeve 604. The retaining member 700includes a lip 704 that is wider than the shoulder 612. The lip 704 andthe shoulder 612 interact to prevent the retaining member 700 fromexiting the first end 607 of the pin sleeve 604. In hub assemblieswithout a lip 704 or a shoulder 612, the retaining member 700 may bepushed by the biasing element 800 into the axle bore 606, where it maybecome lost (e.g., by becoming displaced from the hub assembly) ordamaged (e.g., by being crushed by the axle 150). The biasing element800 is disposed within the conduit 610 of the pin sleeve 604. Thebiasing element 800 is configured to bias the retaining member 700towards the axle bore 606 and is configured to operatively engage agroove 152 in an axle 150. The restraining element 900 is configured toprevent the retaining member 700 from exiting the second end 608 of thepin sleeve 604.

FIG. 4C is a cutaway top perspective view of the hub assembly 400, whichshows the interaction between the elements. In some embodiments, thebiasing element 800 within the pin sleeve 604 is in a relaxed position(i.e., the biasing element 800 only applies force to the retainingmember 700 and the restraining element 900 upon being compressed). Incertain embodiments, the biasing element 800 within the pin sleeve 604is in a compressed state such that the biasing element 800 applies forceto the retaining member 700 and the restraining element 900 regardlessof the position of the retaining member 700. The restraining element 900is stationary, but the retaining member 700 can move longitudinallywithin the pin sleeve 604 and compress the biasing element 800. Aportion of the retaining member 700 protrudes through the first end 607of the pin sleeve 604 and through the wheel mounting sleeve 602 and intothe axle bore 606, where it can interact with a groove 152 in an axle150. As an axle 150 is inserted into the axle bore 606, the axle 150pushes the retaining member 700 into the pin sleeve 604. Once the axle150 is extended until the groove 152 is aligned with the retainingmember 700, the retaining member 700, acted upon by the biasing element800, extends out of the pin sleeve 604 and into the groove 152.

FIG. 4D is a side cross-sectional view of the hub assembly 400operatively engaged with the groove 152 of an axle 150. Once engaged,the retaining element 700 interacts with the groove 152 to prevent thehub assembly 400 from becoming detached from the axle 150. If a userwishes to detach the hub assembly 400 from the axle 150, a tool may beinserted into the tool passageway 630. A tool inserted through the toolpassageway 630 may act on the retaining element 700 to extend it towardsthe second end 608 of the pin sleeve 604 and out of the axle bore 606,at which point the axle 150 may be slid out of the axle bore 606. Insome embodiments, a tool may act on the lip 704 of the retaining element700 (e.g., acting as a wedge or lever to cause the retaining element 700to move). In some embodiments, a tool may pierce or puncture theretaining element 700 such that movement of the tool causes acorresponding movement of the retaining element 700. Other interactionsbetween a tool and the retaining element 700 are also possible (e.g., atool may fit into a slot of a retaining element 700).

In certain embodiments, a membrane (or “puncture skin”) 632 may at leastpartially cover the tool passageway 630. The membrane 632 is preferablythin enough to be punctured by the tool prior to engagement with theretaining member 700 (e.g., about 0.01 inch thick). The membrane 632 canprovide evidence of tampering with the hub assembly 400. The membrane632 may also disguise access to the retaining member 700, such that onlya person having knowledge of the hub assembly 400 is able to detach thehub assembly 400 from the axle 150. Although illustrated as being in aportion of the tool passageway 630 proximate to the conduit 610, themembrane 632 may be flush with the end wall 614 or elsewhere. The toolpassageway 630 may be raised with respect to the end wall 614 (e.g., bythe lip 634) to identify the tool passageway 630 if covered by amembrane 632 and/or to aid in positioning of the hub assembly 400 intothe wheel 202, 302. Additionally, the components of the hub assembly 400remain together upon intentional or unintentional detachment from awheel 202, 302, which can prevent the retaining element 700 and/or thebiasing element 800 from becoming lost or damaged.

Certain hub assemblies known in the art leave the second end of the pinsleeve open, which allows the retaining member and/or the biasingelement to exit the second end of the pin sleeve when the hub assemblyis not coupled to a wheel. Such wheel assemblies thus requiresimultaneous assembly of the components of the hub assembly andattachment of the hub assembly to the wheel. Similarly, damage to thewheel assembly resulting in detachment of the hub assembly from thewheel can cause the components of the hub assembly to exit the pinsleeve, whereupon they may be lost and/or damaged. By contrast, therestraining element 900 of certain embodiments of the present inventioncan prevent the retaining member 700 and/or the biasing element 800 fromexiting the second end 608 of the pin sleeve 604. Accordingly, thecomponents of the hub assembly 400 may be assembled at a first point intime, and later mechanically coupled to a wheel 202, 302. This allowsfor more modular assembly of the wheel assemblies 200, 300. For example,a factory may produce a plurality of wheels 202, 302 one day and aplurality of hub assemblies 400 another day, and then couple the wheels202, 302 and the hub assemblies 400 at a later time. Such flexibilityallows formation of the components in various orders and based onparticular supplies or demands at certain periods of time.

Because hub assemblies known in the art that leave the second end of thepin sleeve open allow the retaining member and/or the biasing element toexit the second end of the pin sleeve when the hub assembly is notcoupled to a wheel, automation of the coupling of the hub assembly to awheel is limited. By contrast, the restraining element 900 of certainembodiments of the present invention can prevent the retaining member700 and/or the biasing element 800 from exiting the second end 608 ofthe pin sleeve 604. Accordingly, the hub assembly 400 will not separateinto its components upon manipulation by certain automating equipment(e.g., a vibratory feeder). Moreover, the hub assembly 400 can betransported, dropped, or otherwise manipulated without requiringreassembly.

FIGS. 5A through 5D illustrate cutaway and cross-sectional views of thewheel assemblies 200, 300. In certain embodiments, a method ofmanufacturing the wheel assemblies 200, 300 comprises forming a wheel202, 302, forming a retainer housing 600, positioning a retaining member700 within the pin sleeve 604, positioning a biasing element 800 in thepin sleeve 608, occluding the second end 608 of the pin sleeve 604(e.g., with a restraining element 900), and inserting the wheel mountingsleeve 602 into the sleeve bore 210, 310. As described above, occlusionof the second end 608 of the pin sleeve 604 prevents the retainingmember 700 from exiting the second end 608 of the pin sleeve 604, evenwhen the hub assembly 400 is not coupled to the wheel 202, 302.Accordingly, formation of the retainer housing 600, positioning theretaining member 700, positioning the biasing element 800, and occludingthe second end 608 of the pin sleeve 608 may be performed before orafter forming the wheel 202, 302. Coupling the hub assembly 400 and thewheel 202, 302 may be while either or both of the pieces is/are warm orcold, depending on the relative deformability of the components (e.g.,due to thickness or configuration), the desired post-assembly expansioncharacteristics, etc. In some embodiment, the wheel 202 is deflashedprior to being coupled to the hub assembly 400.

The modularity of the hub assembly 400 described above alsoadvantageously can allow the restraining element 900 to be separate anddistinct from any portions of the wheel 202, 302 (e.g., a wall 220, 320of the wheel 202, 302, respectively). The biasing element 800 maytherefore be displaced from the wall 220, 320 by at least a space or gap402. In certain alternative embodiments, the restraining element 900 ispositioned to touch the wall 220, 320. In certain alternativeembodiments, the biasing element 800 is positioned to touch the wall220, 320 (e.g., by occluding the second end 608 of the pin sleeve 604 ata position in a middle portion of the biasing element 800).

FIG. 5E illustrates a cross-sectional view of a wheel assembly 300engaged with an axle 150 and a cart body 102, although it will beappreciated that the wheel assembly 200 or other wheel assemblies wouldlook similar. In certain embodiments, the inner side of the wheelassemblies 300 described herein can rub against the cart body 102.Friction from such rubbing can increase the force needed to move therefuse cart 100, can cause damage to the wheel assembly 300 and/or thecart body 102, and other problems. In some embodiments, a spacer (e.g.,comprising a pipe) is placed between the wheel assembly 300 and the cartbody 102 to space the wheel assembly 300 from the cart body 102 by adistance d. In certain embodiments, the retainer housing 600 comprises aspacer 640 extending from the wheel mounting sleeve 602. The spacer 640is configured to space the wheel assembly 300 from the cart body 102 bya distance d. In certain such embodiments, the spacer 640 is integrallyformed with the retainer housing 600. Such integral forming can increasethe strength of the junction or interface between the spacer 640 and thewheel mounting sleeve 602 versus embodiments in which the spacer 640 iscoupled (e.g., welded) to the wheel mounting sleeve 602. Integralforming can also ensure correct sizing of the spacer 640, for example tohave a suitable interface with the wheel mounting sleeve 602 and/or thedesired distance d from the cart body 102. Spacers can also bepositioned elsewhere between the wheel assembly 300 and the cart body102 (e.g., integrated with the wheel 302).

FIG. 6A illustrates a cross-sectional view of an example embodiment of aretainer housing 600. The retainer housing 600 includes a wheel mountingsleeve 602 and a pin sleeve 604. In certain embodiments, the wheelmounting sleeve 602 is substantially cylindrical. In some embodiments,the pin sleeve 604 is substantially cylindrical. The wheel mountingsleeve 602 includes an axle bore 606 configured to receive an axle 150and configured to be inserted within the sleeve bore 210, 310 of a wheel202, 302. The pin sleeve 604 includes a first end 607, a second end 608,and a conduit 610 therebetween. In certain embodiments, the conduit 610is substantially cylindrical. When assembled, the first end 607 is influid communication with the axle bore 606. The first end 607 includes ashoulder 612 extending into the conduit 610. In some embodiments, theshoulder 612 may prevent the retaining member 700 from exiting the firstend 607 of the pin sleeve 604 (e.g., in conjunction with a lip 704 of aretaining member 700). In the illustrated embodiment, the wheel mountingsleeve 602 is closed at one end such that an axle 150 inserted into theaxle bore 606 is not visible on the outer surface of a wheel assembly200, 300 comprising the hub assembly 400 and an axle 150.

In certain embodiments, the retainer housing 600 includes an end wall614. The side illustrated in FIG. 6A is on the outer side of a wheelassembly 200, 300 (FIGS. 2A and 3A). In some embodiments, the end wall614 includes text or a logo (e.g., indicative of a manufacturer of thewheel, wheel assembly, and/or hub assembly, indicative of a type ofwheel and/or hub assembly, etc.). In some embodiments, the end wall 614is shaped to appear integral with a wheel 200, 300 (e.g., includingsimilarly shaped spokes). In some embodiments, the end wall 614disguises the location of the pin sleeve 604. In certain embodiments,after the hub assembly 400 has been mechanically coupled to the wheel202, 302, the end wall 614 provides substantially equal distribution ofside-shifted loads because the force can be applied substantially allthe way around the wheel 202, 302, as opposed to being concentrated, forexample, at the junction between the wheel mounting sleeve 602 and thepin sleeve 604.

FIG. 6B illustrates the opposite side of the retainer housing 600, whichillustrates that the end wall 614 may include a plurality of raisedprojections 616. The raised projections 616 can provide a number ofadvantages. In certain embodiments, the raised projections 616 mayincrease an amount of surface area that makes contact with the wheel202, 302. In certain embodiments, the raised projections 616 mayproperly orient the retainer housing 600 with the wheel 202, 302. Insome embodiments, the raised projections 616 allow the retainer housing600 to be properly aligned (e.g., in a vibratory feeder) for assembly(e.g., automated assembly) with other components of the hub assembly400. In certain such embodiments, at least some of the plurality ofprojections 616 may have a common endpoint (e.g., as illustrated by thedotted line 618). In some embodiments, the raised projections 616 allowthe hub assembly 400 to be properly aligned (e.g., in a vibratoryfeeder) for assembly (e.g., automated assembly) with other components ofthe wheel assembly 200, 300 (e.g., the wheel 202, 302). In certain suchembodiments, the assembled hub assembly 400 and the wheel 202, 302 maybe automatically assembled (e.g., substantially without humaninteraction). In some embodiments, the raised projections 616 reinforcea junction or interface between the end wall 614 and the wheel mountingsleeve, which can enhance the distribution of loads (e.g., transversetorque caused by movement of the wheel assembly 110 generally along thelongitudinal axis of the axle 150).

In certain embodiments, the retainer housing 600 is injection molded.Injection molding may allow high stricter tolerances than blow moldingbecause the thicknesses of the components may be controlled based on thespacing between the male and female molds. In some embodiments, the endwall 614, the wheel mounting sleeve 602, and the pin sleeve 604 areintegrally formed, although the pieces may also be separately formed andcoupled (e.g., welded). In certain such embodiments in which theelements are integrally formed, injection molding can increasethroughput by reducing the number of downstream steps (e.g., eliminatingtrimming steps because the bores 604, 606 may be formed open at bothends). Other features of the retainer housing 600 may also be integrallyformed (e.g., the raised projections 616). In certain embodiments, theretainer housing 600 comprises plastic (e.g., high density polyethylene(HDPE) (e.g., high molecular weight HDPE)).

In some embodiments, the wheel mounting sleeve 602 comprises an annularrib 620 configured to engage a sidewall 230, 330 of a wheel 202, 302,respectively (FIGS. 5B and 5D). The rib 316 has a width that is widerthan the width of the sleeve bore 402. In certain embodiments, the wheelmounting sleeve 602 is press-fit into the sleeve bore 210, 310 of awheel 202, 302 until the annular rib 620 resiliently snaps out from thesleeve bore 210, 310. In certain such embodiments, the wheel mountingsleeve 602 does not comprise slots. In certain alternative embodiments,the the annular rib 620 comprises at least one axial slot 622 that canfacilitate passage of the annular rib 620 through the sleeve bore 210,310. The at least one axial slot 622 can also extend into the wheelmounting sleeve 602, although there may be a tradeoff between theflexibility and strength of and the wheel mounting sleeve 602. Incertain embodiments, the annular rib 620 comprises two axial slots 622and a tooth 624 between the axial slots 622. In a relaxed position, thetooth 624 has a width that is wider than the sleeve bore 210, 310. Theaxial slots 622 thus can assist in radially inward flexing of the tooth624 as it is urged through the sleeve bore 210, 310.

FIG. 7 illustrates an example embodiment of a retaining member 700. Insome embodiments, the retaining member 700 comprises a pin. Theretaining member 700 is configured to operatively engage a groove 152 inan axle 150. In certain embodiments, an axle 150 has a chamfered endsuch that the retaining member 700 is transversely displaced relative tothe movement of the axle 150. In certain alternative embodiments, theretaining member 700 is shaped (e.g., chamfered) such that it istransversely displaced relative to the movement of an axle 150 (e.g.,without a chamfered end). In some embodiments, the retaining member 700is configured (e.g., dimensioned) to reduce (e.g., decrease, minimize,prevent) rubbing of the sides of the groove 152 in the axle 150 by thesides of the retaining member 700.

In some embodiments, the retaining member 700 comprises metal (e.g.,stainless steel), which is may be more resistant to damage from typicalusage of the wheel assembly 200, 300 than plastic. Metal may also bebetter suited to shock loading and vibration than plastic. However,other materials (e.g., plastic) are also possible. In some embodiments,the retaining member 700 includes a central body 702 and a lip 704extending outwardly from the central body 702. In certain suchembodiments, the lip 704 is wider than the shoulder 612 of the first end607 of the pin sleeve 604 and narrower than the conduit 610, and islongitudinally positioned along the central body 702 such that only aportion of the retaining member 700 extends into the axle bore 606. Theshoulder 612 may prevent the retaining member 700 from exiting the firstend 607 of the pin sleeve 604 by interacting with the lip 704 in suchembodiments. Other shapes and types of retaining members 700 are alsopossible. For example, the retaining member 700 may be shaped to alwayshave a certain orientation within the conduit 610 (e.g., having a flatside 750 that prevents rotation of the retaining member 700 within theconduit 610, as illustrated in FIG. 7B). Such an embodiment may beuseful for proper engagement of a chamfered retaining member 700, asillustrated by the portion 752 in FIG. 7, with a non-chamfered axle 150.For another example, the lip 704 may be longitudinally thicker, whichcan stabilize the retaining member 700, as illustrated in FIG. 7A, byreducing the chance of the retaining member 700 pivoting within theconduit 610. Other possible shapes include those that aid in engagingthe retaining member 700 with the biasing element 800.

FIG. 8 illustrates an example embodiment of a biasing element 800. Thebiasing element 800 is configured to bias the retaining member 700towards the axle bore 606. In some embodiments, the biasing element 800comprises a spring. In some embodiments in which the biasing element 800comprises a spring, a first end 802 mechanically engages the lip 704 ofthe retaining member 700 and the second end 804 mechanically engages theshoulder 902 of the restraining element 900 to bias the retaining member700 towards the axle bore 606. In some embodiments, the biasing element800 comprises metal (e.g., stainless steel), which is may be moreresistant to damage from typical usage of the wheel assembly 200, 300than plastic and which may be better suited to shock loading andvibration than plastic. However, other materials (e.g., plastic) arealso possible. Other shapes and types of biasing elements 800 are alsopossible. In certain embodiments, the retaining member 700 and thebiasing element 800 are disposed in a cartridge that can be disposed inthe pin sleeve 604. However, it will be appreciated that addingnon-essential layers such as the cartridge body would not depart fromthe invention disclosed herein.

FIGS. 9A and 9B illustrate an example embodiment of a restrainingelement 900. The restraining element 900 is configured to prevent theretaining member 700 from exiting the second end 608 of the pin sleeve604. In some embodiments, the restraining element 900 comprises a plug(e.g., as illustrated in FIGS. 4A-5D). In some embodiments in which therestraining element 900 comprises a plug, the plug is mechanicallycoupled to the second end 608 of the pin sleeve 604. The illustratedplug 900 comprises a shoulder 902 and a lip 904. The shoulder 902 isconfigured to mechanically engage the second end 804 of a biasingelement 800. The lip 904 is configured to mechanically engage the pinsleeve 604. After the retaining member 700 and the biasing element 800are disposed in the pin sleeve 604, the plug 900 may be welded (e.g.,heat welded, ultrasonic welded) or otherwise affixed (e.g., adhered,mechanically forced, etc.) to the pin sleeve 604. In some embodiments,the retaining element 900 comprises molded (e.g., blow molded orinjection molded) plastic, although other materials are also possible.Other shapes and types of restraining elements 900 are also possible.For example, the restraining element 900 may be mechanically coupled(e.g., welded) to the biasing element 800 prior to assembly in the hubassembly 400. FIGS. 10A-10D illustrate further example embodiments ofhub assemblies comprising different types of restraining elements 900.

FIG. 10A illustrates an embodiment of a hub assembly 1002 in which therestraining element 900 comprises an indentation in the second end 608of the pin sleeve 604. After the retaining member 700 and the biasingelement 800 are disposed in the pin sleeve 604, the second end 608 ofthe pin sleeve 604 is deformed (e.g., heat deformed). The deformation900 is configured to prevent the retaining member 700 from exiting thesecond end 608 of the pin sleeve 604 (e.g., by being narrower than thebiasing element 800 such that the second end 804 of the biasing element800 is mechanically engaged therewith). The deformation may be allaround the pin sleeve 604, in a single location, in a plurality oflocations, etc.

FIG. 10B illustrates an embodiment of a hub assembly 1004 in which therestraining element 900 comprises a disc configured to be insertedproximate to the second end 608 of the pin sleeve 604. After theretaining member 700 and the biasing element 800 are disposed in the pinsleeve 604, the disc 900 is inserted (e.g., into a pin sleeve window630). The disc 900 may be welded (e.g., heat welded, ultrasonic welded)or otherwise affixed (e.g., adhered, mechanically forced, etc.) to thepin sleeve 604. The disc 900 is configured to prevent the retainingmember 700 from exiting the second end 608 of the pin sleeve 604 (e.g.,by blocking the second end 608 of the pin sleeve 604 such that thesecond end 804 of the biasing element 800 is mechanically engagedtherewith).

FIG. 10C illustrates an embodiment of a hub assembly 1006 in which therestraining element 900 comprises a plurality of ledges 900 extendinginto the pin bore 610. The ledges 900 may be formed before or after theretaining member 700 and biasing element 800 are disposed in the pinsleeve 604. For example, if formed before (e.g., by being integrallymolded with the retainer housing 600, as illustrated in FIG. 10C), theymay be pliable to the insertion of the retaining member 700 and biasingelement 800, but rigid against the removal of the retaining member 700and biasing element 800. The ledges 900 are configured to prevent theretaining member 700 from exiting the second end 608 of the pin sleeve(e.g., by extending into the pin bore 610 wider than the biasing element800 such that the second end 804 of the biasing element 800 ismechanically engaged therewith).

FIG. 10D illustrates an embodiment of a hub assembly 1008 in which therestraining element 900 comprises a plug 900 including threads 906. Insuch an embodiment, the second end 608 of the pin sleeve 604 may alsocomprise threads (e.g., complementary threads). As described above withrespect to the plug 900 of FIGS. 9A and 9B, the plug 900 comprises ashoulder 902 configured to mechanically engage the second end 804 of thebiasing element 800 and a lip 904 configured to mechanically engage thesecond end 608 of the pin sleeve 604. After the retaining member 700 andthe biasing element 800 are disposed in the pin sleeve 604, the plug 900is threaded into the pin sleeve 604. In certain embodiments, the plug900 comprises a fastening device 908 (e.g., a hexagonal hole asillustrated in FIG. 10D, a screwdriver slot, etc.) in which transverseforce on the plug 900 causes it to be screwed into the pin sleeve 604.It will be appreciated that the restraining elements 900 illustratedherein are for example purposes only, and that a variety of otherrestraining elements are also possible.

Although this invention has been disclosed in the context of certainembodiments and examples, it will be understood by those skilled in theart that the present invention extends beyond the specifically disclosedembodiments to other alternative embodiments and/or uses of theinvention and obvious modifications and equivalents thereof. Inaddition, while several variations of the invention have been shown anddescribed in detail, other modifications, which are within the scope ofthis invention, will be readily apparent to those of skill in the artbased upon this disclosure. It is also contemplated that variouscombinations or sub-combinations of the specific features and aspects ofthe embodiments may be made and still fall within the scope of theinvention. It should be understood that various features and aspects ofthe disclosed embodiments can be combined with, or substituted for, oneanother in order to form varying modes of the disclosed invention. Thus,it is intended that the scope of the present invention herein disclosedshould not be limited by the particular disclosed embodiments describedabove, but should be determined only by a fair reading of the claimsthat follow.

What is claimed is:
 1. A wheel assembly comprising: a wheel including asleeve bore; and a hub assembly mounted in the wheel, the hub assemblyincluding: a retainer housing including: a wheel mounting sleeveincluding an axle bore configured to receive an axle and configured tobe inserted within the sleeve bore of the wheel; and a pin sleeveincluding a first end, a second end, and a conduit between the first endand the second end, the first end in fluid communication with the sleevebore, the first end including a shoulder extending into the conduit; aretaining member disposed within the conduit of the pin sleeve, theretaining member including a lip wider than the shoulder, the lip andthe shoulder interacting to prevent the retaining member from exitingthe first end of the pin sleeve; a biasing element disposed within theconduit of the pin sleeve and configured to bias the retaining membertowards the axle bore, the retaining member configured to operativelyengage a groove in an axle; and a restraining element configured toprevent the retaining member from exiting the second end of the pinsleeve.